Impact cutter blade and holder system and method

ABSTRACT

An impact cutter blade and holder system is disclosed. The impact cutter blade and holder system includes: a cutter disk, a plurality of impact holders, and a plurality of impact cutter blades. The cutter disk has a central axis about which the cutter disk is configured to rotate. The plurality of impact holders are secured to the cutter disk. The plurality of impact cutter blades is secured to the plurality of impact holders.

TECHNICAL FIELD

The present disclosure generally relates to an Impact Cutter Blade andHolder system and method. More particularly, the present disclosurerelates to an Impact Cutter Blade and Holder system and method thatreduces maintenance and improves performance by protecting itscomponents from collisions with comminution material.

DESCRIPTION OF THE RELATED ART

There exists a need in many industries to reduce large pieces of solidmaterial to a particulate form. For instance, in managing wood and treewaste, it is desirable to grind stumps, branches, and wood scraps intosmaller wood chips. Wood chips are more easily and efficientlytransported, stored, and used for a variety of purposes. In otherinstances, it is desirable to reduce large pieces of waste material,such as plastic, for recycling or disposal. In still other instances, itis desirable to reduce pieces of rock, metal, asphalt, or otherextremely hard material, for disposal.

Refiners of various size and operation are generally available forperforming this function. One style of refiner includes a refiningchamber defined by a sidewall and a bottom floor at one end of thesidewall. An annular ring in the same plane and surrounding the bottomfloor is attached to the sidewall and rotates with the sidewall. Forinstance, a refiner of this style may include a comminuting chamber inwhich a rotatably-mounted cutter disk with attached blades impacts solidmaterial introduced into the chamber and reduces the material toparticulate form.

Some such refiners operate by rotating both the chamber sidewall and thebladed cutter disk, sometimes in the same direction, and sometimes inopposite directions. The rotation of the sidewall imparts rotationalmotion to the solid material placed in the chamber. As the material inthe chamber rotates with the chamber sidewall, the material comes intocontact with the rotating cutter disk. The blades of the cutter diskimpact the material, thereby ripping and tearing the material intosuccessively smaller pieces. The annular portion of the bottom of thechamber that rotates with the sidewall typically includes a screenedexit through which the material, once refined to a particular size, maypass out of the chamber.

The old style blades of the cutter disks were held in place by a“backer” (i.e., a short hardened key stock) and a “keeper” (i.e., ahardened wedge). In prior blade and swing lock holder assemblies, ablade was inserted into a slot of the holder, and then wedged intoplace. The various components of these traditional cutter disks wouldbecome damaged on a regular basis due to the constant collision with thecomminution material. When the various components of these traditionalcutter disks had to be replaced or repaired due to damage from thecomminution material, the maintenance costs were sizeable and themaintenance time periods were protracted.

There is a continuing need in the art for a cutter disk and associatedcomponents that are more protected from impact damage caused by thecomminution material and contaminates in the material, which results inincreased maintenance and reduced performance of the refiner.

Notably, all of the subject matter discussed in this section is notnecessarily prior art and should not be assumed to be prior art merelyas a result of its discussion in this section. Accordingly, anyrecognition of problems in the prior art discussed in this section orassociated with such subject matter should not be treated as prior artunless expressly stated to be prior art. Instead, the discussion of anysubject matter in this section should be treated as part of theidentification of the technological problem to be overcome, which in andof itself may also be inventive.

BRIEF SUMMARY

One embodiment of an impact cutter blade and holder system may besummarized as including: a cutter disk having a central axis about whichthe cutter disk is configured to rotate; a plurality of impact holders,wherein each of the plurality of impact holders is secured to the cutterdisk via bolts; a plurality of impact cutter blades, wherein anassociated impact cutter blade of the plurality of impact cutter bladesis secured to an associated impact holder of the plurality of impactholders; a plurality of wear slugs, wherein an associated wear slug ofthe plurality of wear slugs is secured to an associated impact holder ofthe plurality of impact holders, wherein the associated wear slug isshaped, sized, and securely positioned to shield the associated impactholder of the plurality of impact holders from damage by comminutionmaterial; a plurality of impact tabs, wherein an associated impact tabof the plurality of impact tabs is secured between an associated impactholder and associated impact cutter blade, wherein the associated impacttab of the plurality of impact tabs is shaped, sized, and securelypositioned to shield the associated impact holder from a trailing edgeof the associated impact cutter blade, due to collision of theassociated impact cutter blade with the comminution material; and a diskwear cover plate secured to the cutter disk, wherein the disk wear coverplate is shaped and sized to shield the cutter disk and the securedplurality of impact holders from damage by comminution material.

Another embodiment of an impact cutter blade and holder system may besummarized as including: a cutter disk having a central axis about whichthe cutter disk is configured to rotate; a plurality of impact holders,wherein each of the plurality of impact holders is secured to the cutterdisk via bolts; a plurality of impact cutter blades, wherein anassociated impact cutter blade of the plurality of impact cutter bladesis secured to an associated impact holder of the plurality of impactholders; a plurality of wear slugs, wherein an associated wear slug ofthe plurality of wear slugs is secured to an associated impact holder ofthe plurality of impact holders, wherein the associated wear slug isshaped, sized, and securely positioned to shield the associated impactholder of the plurality of impact holders from damage by comminutionmaterial.

Each of the plurality of impact holders may contain a holder bolt holefor receiving a blade bolt, and a blade mounting slot for receiving aheld end of an impact cutter blade. The associated impact holder of theplurality of impact holders may include a push-slug bolt, wherein thepush-slug bolt tightens the associated wear slug in place. Theassociated wear slug is mounted on the leading side of the associatedimpact holder via a machine fit. The associated impact cutter blade ofthe plurality of impact cutter blades may have a leading edge positionedto collide with comminution material and a trailing edge opposite theleading edge, the associated impact cutter blade may have a cutter endthat is located away from the associated impact holder and a held endthat is secured in the associated impact holder. The associated impactcutter blade of the plurality of impact cutter blades may contain ablade bolt hole for securing the associated impact cutter blade to theassociated impact holder using the blade bolt hole and a blade bolt.

The associated impact cutter blade of the plurality of impact cutterblades may be secured through the blade bolt hole of the associatedimpact cutter blade to the associated impact holder using the blade boltand a stepped nut, wherein the stepped nut may have a lower portion anda stepped portion that is raised higher than the lower portion of thestepped nut, wherein the stepped portion of the stepped nut may contactthe impact cutter blade on a trailing edge of the blade bolt hole. Theassociated impact cutter blade of the plurality of impact cutter bladesmay include a ridge (e.g., pivot weld) that runs along a length of theassociated impact cutter blade and acts as a fulcrum when the associatedimpact cutter blade is secured in a blade mounting slot of theassociated impact holder. When the blade bolt is tightened against thestepped nut, leverage is generated against the fulcrum that forces aleading edge of the associated impact cutter blade against a forwardopposite side of the blade mounting slot in the impact holder. Thisleverage provides tension that keeps the blade bolt from coming loose.Additionally, a hex hole holds the nut so that the blade bolt can beremoved with only one wrench.

The associated wear slug of the plurality of wear slugs may be mountedto the leading side of the associated impact holder via a machine fit.The push-slug bolt tightens the associated wear slug in place. Theassociated wear slug is tapered from its smallest end by the push boltto its largest end at the machine fit to the associated impact holder.The associated wear slug of the plurality of wear slugs is larger indiameter than the associated impact holder. As such, the associated wearslug presents a larger profile to incoming comminution material than theassociated impact holder, and the associated wear slug may protect theassociated impact holder by shielding the associated impact holder fromcollisions with the incoming comminution material that would otherwisedamage the associated impact holder. The associated wear slug that ismounted on the associated impact holder may only expose a third of acircumference of the associated wear slug to collision with thecomminution material, and the associated wear slug may be rotatable tothree separate positions while shielding the associated impact holder,each position representing a third of the circumference of theassociated wear slug.

Still another embodiment of an impact cutter blade and holder system maybe summarized as including: a cutter disk having a central axis aboutwhich the cutter disk is configured to rotate; a plurality of impactholders, wherein each of the plurality of impact holders is secured tothe cutter disk via bolts; a plurality of impact cutter blades, whereinan associated impact cutter blade of the plurality of impact cutterblades is secured to an associated impact holder of the plurality ofimpact holders; and a plurality of impact tabs, wherein an associatedimpact tab of the plurality of impact tabs is secured between anassociated impact holder and associated impact cutter blade, wherein theassociated impact tab of the plurality of impact tabs is shaped, sized,and securely positioned to shield the associated impact holder from atrailing edge of the associated impact cutter blade, due to collision ofthe associated impact cutter blade with the comminution material.

Each of the plurality of impact holders may contain a holder bolt holefor receiving a blade bolt, and a blade mounting slot for receiving aheld end of an impact cutter blade. The associated impact holder mayfurther include an impact tab locating notch for locating an associatedimpact tab, wherein the impact tab locating notch is at substantiallywider than the trailing edge of the associated impact cutter blade. Theassociated impact cutter blade of the plurality of impact cutter bladesmay have a leading edge positioned to collide with comminution materialand a trailing edge opposite the leading edge, the associated impactcutter blade may have a cutter end that is located away from theassociated impact holder and a held end that may be secured in theassociated impact holder. The associated impact cutter blade of theplurality of impact cutter blades may include an impact tab securingnotch on the trailing edge of the associated impact cutter blade.

The associated impact cutter blade of the plurality of impact cutterblades may contain a blade bolt hole for securing the associated impactcutter blade to the associated impact holder using the blade bolt holeand a blade bolt. The associated impact cutter blade of the plurality ofimpact cutter blades may be secured through the blade bolt hole of theassociated impact cutter blade to the associated impact holder using theblade bolt and a stepped nut, wherein the stepped nut may have a lowerportion and a stepped portion that is raised higher than the lowerportion of the stepped nut, the stepped portion of the stepped nut maycontact the impact cutter blade on a trailing edge of the blade bolthole.

The associated impact cutter blade of the plurality of impact cutterblades may include a ridge (e.g., pivot weld) that runs along a lengthof the associated impact cutter blade and acts as a fulcrum when theassociated impact cutter blade is secured in a blade mounting slot ofthe associated impact holder. When the blade bolt is tightened againstthe stepped nut, leverage is generated against the fulcrum that forces aleading edge of the associated impact cutter blade against a forwardopposite side of the blade mounting slot in the impact holder. Thisleverage provides tension that keeps the bolt from coming loose.Additionally, the hex hole holds the nut so that the blade bolt can beremoved with only one wrench. The associated impact tab of the pluralityof impact tabs may shield the associated impact holder from damagecaused by a trailing edge of the associated impact cutter blade when theassociated impact cutter blade encounters the comminution material. Theassociated impact tab may be positioned in an impact tab securing notchin a trailing edge of the associated impact cutter blade, between theassociated impact cutter blade and the associated impact holder, and theassociated impact tab may be positioned in an impact tab locating notchof the associated impact holder.

A leading end of the associated impact tab may abut the impact tabsecuring notch in the trailing edge of the associated impact cutterblade, while a trailing end of the associated impact tab may abut theimpact tab locating notch of the associated impact holder. Theassociated impact cutter blade of the plurality of impact cutter bladesmay have an impact tab securing notch with a 90-degree angle in atrailing edge of the associated impact cutter blade that holds theassociated impact tab in place, the 90-degree angle of the impact tabsecuring notch may enable the associated impact tab to support theassociated impact cutter blade against both radial force and tangentialforces. The associated impact tab of the plurality of impact tabs mayhave a larger width than a trailing edge of the associated impact cutterblade, wherein the larger width of the associated impact tab spreads outand diminishes forces transmitted by the associated impact cutter bladetowards the associated impact holder due to collision of the associatedimpact cutter blade with the comminution material.

The associated impact tab of the plurality of impact tabs may be formedfrom a metallic alloy that is softer than the associated impact holdersuch that force from the associated impact cutter blade deforms theassociated impact tab before the associated impact holder.

Yet another embodiment of an impact cutter blade and holder system maybe summarized as including: a cutter disk having a central axis aboutwhich the cutter disk is configured to rotate; a plurality of impactholders, wherein each of the plurality of impact holders is secured tothe cutter disk via bolts; a plurality of impact cutter blades, whereinan associated impact cutter blade of the plurality of impact cutterblades is secured to an associated impact holder of the plurality ofimpact holders; and a disk wear cover plate secured to the cutter disk,wherein the disk wear cover plate is shaped and sized to shield thecutter disk and the secured plurality of impact holders from damage bycomminution material.

The disk wear cover plate may be secured to the cutter disk using platemounting bolts, and the disk wear cover plate may reduce friction,energy consumption, and fuel consumption since collision against thedisk wear cover plate by the comminution material is oblique rather thandirect.

In still another embodiment, an impact cutter blade clamping method thatemploys an impact cutter blade and holder system is disclosed. Theimpact cutter blade clamping method includes: providing a cutter diskand a plurality of impact holders, wherein the cutter disk has a centralaxis about which the cutter disk is configured to rotate, and whereineach of the plurality of impact holders is secured to the cutter disk;configuring the plurality of impact holders to include blade mountingslots, wherein each blade mounting slot includes sidewalls and is shapedand sized to receive an impact cutter blade, and wherein the impactcutter blade includes two impact cutter blade sidewalls and a leadingedge that is positioned to intersect with comminution material when thecutter disk rotates; positioning a ridge on at least one of an impactcutter blade sidewall or a blade mounting slot sidewall of an associatedimpact holder of the plurality of impact holders; placing the impactcutter blade in the blade mounting slot of the associated impact holder;clamping, using a blade bolt, the impact cutter blade to the associatedimpact holder and against the ridge, which acts as a fulcrum thatreduces vibration and provides increased rigidity at the leading edge ofthe impact cutter blade; and generating leverage against the fulcrumthat forces the leading edge of the associated impact cutter bladeagainst a forward opposite sidewall of the blade mounting slot in theassociated impact holder.

In another aspect of the impact cutter blade clamping method, a bladebolt is tightened against a stepped nut that is positioned opposite ofthe ridge on at least one of an impact cutter blade sidewall or a blademounting slot sidewall of an associated impact holder of the pluralityof impact holders.

These features with other technological improvements, which will becomesubsequently apparent, reside in the details of construction andoperation as more fully described hereafter and claimed, reference beinghad to the accompanying drawings forming a part hereof.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The present disclosure will be more fully understood by reference to thefollowing figures, which are for illustrative purposes only. Thesenon-limiting and non-exhaustive embodiments are described with referenceto the following drawings, wherein like labels refer to like partsthroughout the various views unless otherwise specified. The sizes andrelative positions of elements in the drawings are not necessarily drawnto scale. For example, the shapes of various elements are selected,enlarged, and positioned to improve drawing legibility. The particularshapes of the elements as drawn have been selected for ease ofrecognition in the drawings. The figures do not describe every aspect ofthe teachings disclosed herein and do not limit the scope of the claims.

FIG. 1 is a perspective view of one exemplary embodiment of a pan andcutter disk refiner.

FIG. 2A is a perspective view of an embodiment of the impact cutterblade and holder system including a cutter disk, impact holders, impactcutter blades, wear slugs, and impact tabs.

FIG. 2B is a perspective view of two impact holders, each with anattached impact cutter blade, wear slug, and impact tab.

FIG. 3A is a top view of a portion of an impact holder, with an attachedimpact cutter blade, blade bolt, stepped nut, blade washer, wear slug,and impact tab.

FIG. 3B is a perspective view of impact cutter blade shown in FIG. 3A.

FIG. 3C is an end view of a wear slug, push-slug bolt, thick impactcutter blade with a top-side fulcrum, impact holder, impact tab, bladebolt hole, and a stepped nut.

FIG. 3D is an end view of a thick impact cutter blade with a top-sidefulcrum, impact holder, impact tab, blade bolt hole, and a stepped nut.

FIG. 3E is an end view of a thin impact cutter blade with a top-sidefulcrum and a bottom-side fulcrum, impact holder, impact tab, blade bolthole, and a stepped nut.

FIG. 3F is an end view of an impact cutter blade without a fulcrum,impact holder with a bottom-facing fulcrum on the of the top side of theblade mounting slot, impact tab, blade bolt hole, and a stepped nut.

FIGS. 4A-4K are top views of various examples of impact cutter blade forvarious type of comminution materials.

FIG. 5 is a top view of a wear slug.

FIG. 6 is a perspective view of an embodiment of the impact cutter bladeand holder system including a cutter disk, impact holders, impact cutterblades, wear slugs, impact tabs, and a disk wear cover plate.

DETAILED DESCRIPTION

Persons of ordinary skill in the art will understand that the presentdisclosure is illustrative only and not in any way limiting. Otherembodiments of the presently disclosed system and method readily suggestthemselves to such skilled persons having the assistance of thisdisclosure.

Each of the features and teachings disclosed herein can be utilizedseparately or in conjunction with other features and teachings toprovide an impact cutter blade and holder system and method.Representative examples utilizing many of these additional features andteachings, both separately and in combination, are described in furtherdetail with reference to attached FIGS. 1-6. This detailed descriptionis merely intended to teach a person of skill in the art further detailsfor practicing aspects of the present teachings and is not intended tolimit the scope of the claims. Therefore, combinations of featuresdisclosed above in the detailed description may not be necessary topractice the teachings in the broadest sense, and are instead taughtmerely to describe particularly representative examples of the presentteachings.

In the description below, for purposes of explanation only, specificnomenclature is set forth to provide a thorough understanding of thepresent system and method. However, it will be apparent to one skilledin the art that these specific details are not required to practice theteachings of the present system and method.

Moreover, the various features of the representative examples and thedependent claims may be combined in ways that are not specifically andexplicitly enumerated in order to provide additional useful embodimentsof the present teachings. It is also expressly noted that all valueranges or indications of groups of entities disclose every possibleintermediate value or intermediate entity for the purpose of originaldisclosure, as well as for the purpose of restricting the claimedsubject matter. It is also expressly noted that the dimensions and theshapes of the components shown in the figures are designed to help tounderstand how the present teachings are practiced, but not intended tolimit the dimensions and the shapes shown in the examples.

Referring now to FIG. 1, in one embodiment of the present disclosure,the impact cutter blade and holder system is implemented as a refiner,which may be constructed in accordance with the present disclosure.

Alternatively, the impact cutter blade and holder system may also beembodied in a variety of other forms. Typically, a refiner will includea refiner chamber, a cutter disk, an engine that powers the refinerchamber and cutter disk, and a conveyor that carries away the refinedmaterial that has exited the refiner chamber. FIG. 1 is a perspectiveside view of one exemplary embodiment of such a refiner.

The refiner 10 depicted in FIG. 1 includes a rotating refiner chamber 12and a rotating bladed cutter disk located inside the chamber 12. Therefiner 10 includes an engine 14 that powers the operation of therefiner 10. The engine 14 is typically a diesel engine, but other typesof engines, such as a gasoline engine, may be used. Alternatively, or inaddition, other power sources, including electric and hydraulic motors,may be used to operate the refiner 10. The refiner chamber 12 and theengine 14 are mounted on a frame 16 that preferably has wheels 18. Thewheels 18 allow the frame 16 to be transported from one job site toanother. Adjustable jack legs 20 mounted at an end of the frame 16opposite the wheels 18 may be used to maintain the refiner 10 in a levelposition.

In one embodiment, the refiner 10 further includes a conveyor 22 thatcollects and carries away particulate material discharged from therefiner chamber 12. The conveyed particulate material may be depositedin a pile on the ground, in the bed of a truck, and the like.Conventional components may be used to construct the conveyor 22including belt systems, augers, or other mechanisms capable of conveyingthe particulate matter from the refiner chamber 12. See, e.g., thereciprocating screening conveyor described in U.S. Pat. No. 6,000,554,assigned to the assignee of the present disclosure and incorporated byreference herein.

Referring now to FIGS. 2A-6, the impact cutter blade and holder systemand method provides a major technological improvement that reducesoperating costs, reduces maintenance, and improves performance. In someembodiments of the impact cutter blade and holder system 100, the impactcutter blade and holder system 100 includes a cutter disk 110; aplurality of impact holders 130; a plurality of impact cutter blades150, wherein an impact cutter blade 150 is attached to each impactholder 130; a plurality of wear slugs 180, wherein a wear slug 180 isattached to each impact holder 130; a plurality of impact tab 190,wherein an impact tab 190 is secured between each impact holder 130 andassociated impact cutter blade 150; and a disk wear cover plate 200.Notably, the cutter disks 110 of the impact cutter blade and holdersystem 100 may be used in other applications such as attachments forexcavators, wheel loaders, tractors, and the like, as well as portableaxle or tack mounted stump grinders.

The impact cutter blade and holder system 100 is retrofitable to mostcutter disks manufactured since 1990. As shown in FIGS. 2A-2B, theimpact holders 130 of the impact cutter blade and holder system 100secure to the cutter disk 110 in the same way as the traditional “swinglock holders.” However, the impact holders 130 of the impact cutterblade and holder system 100 are attached to wear slugs 180 that provideprotection to the impact holders 130 from comminution material 122,e.g., rock, wood (See FIG. 1), metal, asphalt, and the like, unlike thetraditional “swing lock holders,” which provided no such protection. Theimpact cutter blades 130 of the impact cutter blade and holder system100 secure to the impact holders 130 with the assistance of impact tabs190 that provide protection to the impact holders 130, unlike thetraditional “old style blades,” which provided no such protection.

Referring now to FIG. 2A, the cutter disk 110 of the impact cutter bladeand holder system 100 contains a plurality of through bolt holes 112 forreceiving through bolts 114. In one embodiment, the holder mountingbracket is somewhat horseshoe-shaped. Additionally, the cutter disk 110of the impact cutter blade and holder system 100 contains a central axishole 118 for receiving a central axle (not shown). Further, the cutterdisk 110 of the impact cutter blade and holder system 100 contains aplurality of cover plate holes 202 for securing the disk wear coverplate (described below).

As shown in FIGS. 2A and 2B, each of the plurality of impact holders 130of the impact cutter blade and holder system 100 is connected to thecutter disk 110 using a through bolt 114. Additionally, each impactholder 130 contains a holder bolt hole 132 for receiving a blade bolt. Ahex nut is used to secure the blade bolt on the underside of the impactholder 130. The impact holder 130 of the impact cutter blade and holdersystem 100 also contains a blade mounting slot 134 for receiving a heldend of an impact cutter blade 150, as described in further detail below.

Continuing, each impact holder 130 contains a push-slug bolt 136,wherein the push-slug bolt 136 tightens the associated wear slug 180 inplace, as described in further detail below. The associated wear slug ismounted on the leading side of the associated impact holder via amachine fit. In at least one embodiment, each push-slug bolt 136 istightened to 300-350 ft. lbs. of torque. Notably, the push-slug bolt 136replaces a push bolt in traditional “swing lock holders” that was onlyused to reduce circumferential swing.

As shown in FIG. 3A, the impact holder 130 of the impact cutter bladeand holder system 100 includes a blade removal slot 138, through which alever may be used to remove the impact cutter blade 150 from the impactholder 130. Continuing, the impact holder 130 includes a front-sidecontact point 140 that abuts against the trailing end of the wear slug180. Additionally, the impact holder 130 of the impact cutter blade andholder system 100 includes a back-side contact point 142 which abutsagainst the leading edge of the impact cutter blade 150 that is beingsecured by the impact holder 130.

In some embodiments, the impact holder 130 further includes an impacttab locating notch 144 for locating an impact tab 190, as shown in FIG.3C-3F. Notably, the impact tab locating notch 144 is about twice as wideas the trailing edge of the impact cutter blade 150 to correspond withthe width of the impact tab 190, which is about twice as wide as thetrailing edge of the impact cutter blade 150. In another embodiment, theimpact tab locating notch 144 is more than twice as wide as the trailingedge of the impact cutter blade 150 to correspond with the width of theimpact tab 190, which is more than twice as wide as the trailing edge ofthe impact cutter blade 150. In another embodiment, the impact tablocating notch 144 is at least 150% as wide as the trailing edge of theimpact cutter blade 150 to correspond with the width of the impact tab190, which is at least 150% as wide as the trailing edge of the impactcutter blade 150. Additionally, since the impact holders 130 of theimpact cutter blade and holder system 100 are fabricated from thickerplate than the old style holders, the impact holder 130 of the impactcutter blade and holder system 100 is stronger, heavier, and moremassive than the old style holders.

Referring now to FIGS. 2A, 2B, 3A, and 3B, the plurality of impactcutter blades 150 in the impact cutter blade and holder system 100 eachhave a leading edge 152 (that collides with the comminution material122) and a trailing edge 154 (opposite the leading edge 152, and awayfrom direction of travel of the cutter disk 110). Additionally, eachimpact cutter blade 150 in the impact cutter blade and holder system 100has a cutter end 156 (that is positioned to impact with the comminutionmaterial 122) and a held end 158 (that is secured in the impact holder130). In some embodiments, the plurality of impact cutter blades 150 inthe impact cutter blade and holder system 100 each includes an impacttab securing notch 160 on the trailing edge 154. Each of the pluralityof impact cutter blades 150 contains a blade bolt hole 162 for securingthe impact cutter blade 150 to its associated impact holder 130 usingthe holder bolt hole 132 and a blade bolt.

Referring specifically to FIGS. 3A-3F, in some embodiments of the impactcutter blade and holder system 100, each impact cutter blade 150contains a fulcrum 164 (e.g., pivot weld, ridge, or the like) that runsalong the length of the impact cutter blade 150 (from the held end 158to the cutter end 156). In some embodiments of the impact cutter bladeand holder system 100 that employ a thinner 10 mm impact cutter blade150 a, the impact cutter blade 150 contains a bottom-side ridge 166(e.g., pivot weld, or other fulcrum) on the opposite side of the leadingedge 152 of the held end 158 (as shown in FIG. 3E). This bottom-sideridge 166 enables one size of impact holder 130 to work for both athicker impact cutter blade 150 b (as shown in FIG. 3D) and the thinnerimpact cutter blade 150 a (as shown in FIG. 3E). The bottom-side ridge166 provides a contact line that opposes the fulcrum 164 (e.g., pivotweld, ridge, or the like), while the stepped nut 170 forces the thinnerimpact cutter blade 150 a to compensate for the difference in thickness(from a thicker impact cutter blade 150 b).

In some embodiments of the impact cutter blade and holder system 100,the fulcrum 164 is located on the impact cutter blade 150 (i.e., thefulcrum is a raised portion of the impact cutter blade 150). In such anembodiment, the fulcrum 164 (e.g., pivot weld, ridge, or the like) ismade of a softer metal than the impact holder 130. As such, the fulcrum164 (e.g., pivot weld, ridge, or the like) does not damage the impactholder 130. The fulcrum 164 (e.g., pivot weld, ridge, or the like) maybe replaced at the same time of every impact cutter blade 150 change.

Alternatively, in other embodiments of the impact cutter blade andholder system 100, the holder fulcrum 146 (e.g., pivot weld, ridge, orthe like) is located on the impact holders 130 (i.e., the fulcrum is araised portion inside the impact holder 130), as shown in FIG. 3F. Theholder fulcrum 146 is a bottom-facing fulcrum on the top side of theblade mounting slot. Thus, this alternative embodiment employs a fulcrum146 (e.g., pivot weld, ridge, or the like) as part of the impact holder130 instead of as part of impact cutter blade 150. Notably, in thisalternative embodiment, the fulcrum 146 (e.g., pivot weld, ridge, or thelike) may become damaged more quickly because the impact cutter blade150 is made of a very hard material that would tend to damage a fulcrum146 (e.g., pivot weld, ridge, or the like) on the inside of the impactholder 130 more quickly due to the hardness of the impact cutter blade150. In some embodiments, the impact holder 130 has a very long lifespan, while the impact cutter blade 150 is replaced more frequentlysince it is absorbing the majority of the damage from the comminutionmaterial 122. In various embodiments, the impact cutter blades 150 andimpact holders 130 may be formed by fabrication, casting, forging,forming, and/or any other type of manufacture.

Referring now to another aspect of some embodiments as shown in FIGS. 3Aand 3C-3F, the impact cutter blade and holder system 100 further employsa plurality of stepped nuts 170. Each stepped nut 170 is used to assistin securing an impact cutter blade 150 to an impact holder 130. Thestepped nut 170 has as lower portion and a stepped portion 172 that israised higher than the lower portion of the stepped nut 170. In someembodiments, the stepped portion 172 of the stepped nut 170 abuts theimpact cutter blade 150 on the trailing edge of the blade bolt hole 162(i.e., the side of the blade bolt hole 162 closest to the trailing edge154 of the impact cutter blade 150, away from the direction of travel ofthe cutter disk 110).

Notably, in such an embodiment, the stepped nut 170 causes the clampingof the impact cutter blade 150 in its associated impact holder 130. Asthe blade bolt 174 is tightened against stepped nut 170, leverage isgenerated against the fulcrum 164 (e.g., pivot weld, ridge, or the like)which forces the leading edge 152 of the impact cutter blade 150 againstthe forward opposite side of the blade mounting slot 134 in the impactholder 130. This force clamps the impact cutter blade 150 securely inplace and eliminates any possible vibration of the held end 158 of theimpact cutter blade 150. Continuing, this force deforms the impactcutter blade 150 under extreme spring tension. This tension assures thatthe stepped nut 170, the blade bolt 174, and the impact cutter blade 150do not work loose. This is similar to the effect of a lock washer.

Referring now to FIG. 3B, the leading edge 152 of the impact cutterblade 150 is where nearly all of the impact with the comminutionmaterial 122 is received. As such, the point of maximum rigidity is ator in front of the leading edge 152 of the impact cutter blade 150. Theleading edge 152 of the impact cutter blade 150 lies at or near theextended line of the fulcrum 164 (e.g., pivot weld, ridge, or the like)and the opposing leading edge to provide the needed strength andrigidity.

As the impact cutter blade 150 wears, the leading edge 152 of the impactcutter blade 150 recedes, but the point of maximum rigidity remains ator in front of the leading edge 152 of the impact cutter blade 150. Asthe impact cutter blade 150 slices through the comminution material 122,the impact cutter blade 150 tracks with the comminution material 122 aslong as the point of maximum rigidity remains in front of the extendedline of the fulcrum 164 (e.g., pivot weld, ridge, or the like).

As the blade bolt 174 and stepped nut 170 are tightened, the impactcutter blade 150 is deformed under tension forces to prevent vibration.At the same time, the fulcrum 164 (e.g., pivot weld, ridge, or the like)and opposing leading side become wedged inside the impact holder 130,giving maximum strength to the leading edge 152 of the impact cutterblade 150 where it is needed.

In still another aspect of some embodiments, the impact cutter blade andholder system 100 includes a blade bolt 174 and a blade washer 176. Inat least one specific, non-limiting embodiment, the blade bolt 174 is aGrade 8 fine thread bolt. In some embodiments, the blade bolt 174 istightened to about 400-500 ft. lbs. of torque. In some embodiments, theblade washer 176 is a Grade 8 SAE washer. Notably, the impact cutterblade and holder system 100 does not require the use of a lock washer onthe blade bolt 174, since the stepped nut 170 is held by the hex holeprovided, and blade tension holds the blade bolt 174 and impact cutterblade 150 in place.

In some embodiments of the impact cutter blade and holder system 100,each impact cutter blade 150 is held in place with a single bolt (e.g.,the blade bolt 174) and a single nut (i.e., the stepped nut 170). Inother embodiments, more than one set of blade bolts 174, blade boltholes 162, and stepped nuts 170 are used to fasten a single impactcutter blade 150 to a single impact holder 130.

In one specific, non-limiting embodiment, the blade bolt 174 is a 1.0inch×2.5 inches Grade 8 hex cap screw NF (national fine thread). ThisGrade 8 hex cap screw is a medium carbon alloy tempered steel bolt thatis used where hardness and high strength are desired. In another aspectof a specific, non-limiting embodiment, the blade washer 176 is a 1.0inch SAE (Society of Automotive Engineers) flat washer. In still anotheraspect of a specific, non-limiting embodiment, the stepped nut 170 is a1.0 inch NF hardened high nut with one end shaved away so that only oneside portion presses against the impact cutter blade 150.

In some embodiments of the impact cutter blade and holder system 100,the stepped nut 170 is held from turning by the hex hole so the bladebolt 174 can be removed with only one wrench. The side of the impactholder 130 fits the hex shape of the stepped nut 170 and prevents thestepped nut 170 from turning. Notably, battery powered impact wrenchesare now available with enough power to remove and install the bladebolts 174, making the change of the impact cutter blade 150 veryefficient.

Referring now to FIGS. 4A-4K, the impact cutter blades 150 are availablein a variety of shapes and sizes. Specifically, in various embodimentsof the impact cutter blade and holder system 100, many different stylesof cutter ends 156 are employed on various implementations of impactcutter blades 150 depending on the nature and properties of thecomminution material 122 that is expected to be encountered. The cutterend 156 of the impact cutter blades 150 may be long or short, dull orsharp, depending on the material to be cut.

FIG. 4A illustrates an impact cutter blade 150 (impact super hardwood)having a cutter end 156 that is the shortest and strongest bladedepicted, and is configured for very hard wood, frozen wood andcontaminates such as rock and steel. FIG. 4B illustrates an impactcutter blade 150 (impact hardwood) having a cutter end 156 that is thesecond strongest blade depicted, and is configured for hardwoods andlesser contaminates. FIG. 4C illustrates an impact cutter blade 150(impact softwood) having a cutter end 156 that is the third strongestblade depicted, and is configured for softwoods and lesser contaminates.FIG. 4D illustrates an impact cutter blade 150 (impact ripper) having acutter end 156 that is the fourth strongest blade depicted, and isconfigured for high production in softer, lighter materials. FIG. 4Eillustrates an impact cutter blade 150 (impact long ripper) having acutter end 156 that is the fifth strongest blade depicted, and isconfigured for very high production in lighter materials. FIG. 4Fillustrates an impact cutter blade 150 (impact raker) having a cutterend 156 that is very long, and is configured for clearing grates andhigher production.

FIG. 4G illustrates an impact cutter blade 150 (impact slicer) having acutter end 156 that is very long with a knife edge, and is configuredfor higher production in fibrous materials. FIG. 4H illustrates animpact cutter blade 150 (impact tbc-chipper) having a cutter end 156that is a very aggressive blade with a knife edge, and is configured forhigher production in fibrous materials when less blade strength isrequired. FIG. 4I illustrates an impact cutter blade 150 (knife edge)having a cutter end 156 that has a sharp leading edge, and is configuredfor fibrous materials. FIG. 4J illustrates an impact cutter blade 150(chisel point) having a cutter end 156 that has a sharp chisel point,and is configured for fiberglass and dense plastics. FIG. 4K illustratesan impact cutter blade 150 (club) having a cutter end 156 that hasmassive hardfacing, and is configured for asphalt shingles.

In some embodiments of the impact cutter blade and holder system 100,the impact cutter blades 150 are more massive than previous swing bladesin at least two ways. First, the impact cutter blades 150 of the impactcutter blade and holder system 100 are thicker than previous swingblades (0.5 inches for the impact cutter blade 150 compared to 0.375inches for the previous swing blades).

Second, the impact cutter blades 150 of the impact cutter blade andholder system 100 are wider at the cutter end 156 (where they extend outof the impact holder 130). In one embodiment, the width at the cutterend 156 of the impact cutter blade 150 is 3.25 inches (compared to 2.5inches for the previous swing blades). The strength of the impact cutterblade 150 to resist breakage at the cutter end 156 of the impact cutterblade 150 (i.e., the point at which the impact cutter blade 150 extendsfrom the impact holder 130) is relative to the width times the square ofthe thickness (i.e., for the old style blades the strength is2.5×0.375×0.375=0.352; for the new impact cutter blade 150 the strengthis 3.25×0.5×0.5=0.8125). In some embodiments, the metallic alloyemployed for the impact cutter blade 150 possesses about 220,000 psi(tensile strength). Accordingly, the impact cutter blade 150 is morethan twice as strong as previous swing lock blades.

Referring now to FIGS. 2A, 2B, 3A, 3C, and 5, in another aspect of someembodiments, the impact cutter blade and holder system 100 includes aplurality of wear-absorbing components called wear slugs 180 on theleading side of each impact holder 130. The wear slug 180 is larger thanthe impact holder 130 in diameter and, thus, in the profile that ispresented to incoming comminution material 122. Accordingly, the wearslug 180 absorbs most of the wear that the impact holder 130 wouldotherwise receive from collision with the comminution material 122.

Specifically, the wear slug 180 has a profile that is larger than theprofile of the impact holder 130 (with respect to its contact with thecomminution material 122 that can cause wear). In this regard, thecomminution material 122 advances toward the circumference of the cutterdisk 110 while the cutter disk 110 revolves at a high speed. The impactholder 130 is in the “shadow” of the wear slug 180 so that the surfacesof the impact holder 130 only have minimal contact with the comminutionmaterial 122, while the wear slug 180 takes the full impact of thecomminution material 122 that is encountered. In one embodiment, thewear slug 180 is 4.5 inches in diameter, while the holder profile is 4.0inches in diameter. Thus, the wear slug 180 extends 0.25 inches furthertoward the comminution material 122 than the impact holder 130 in alldirections. The typical advance of the comminution material 122 towardsthe impact holder 130 (in the direction of travel) is about 0.197 inches(which is less than the 0.25 inches that the wear slug 180 extendsbeyond the impact holder 130).

In some embodiments, the wear slug 180 can be turned (rotated) to threepositions (each position representing a third of the wear slug'scircumference) before the wear slug 180 becomes worn out. The wear slug180 is easily removed from the impact holder 130 and cutter disk 110 byloosening the push-slug bolt 136, and can be rehardfaced and reused.This dramatically reduces the amount and difficulty of maintenancerequired for the impact holder 130, since the wear slug 180 is absorbingthe vast amount of the damage which would previously have been impartedonto the impact holder 130.

In one embodiment, the wear slug 180 is turned by loosening thepush-slug bolt 136 with a 1.5 inches end wrench. The wear slug 180 isthen turned manually and the push-slug bolt 136 is re-tightened. Thisconfiguration and adaptability enable a new wear surface of the wearslug 180 to be presented to the direction of travel three times beforethe wear slug 180 must be replaced.

Referring now to FIG. 5, in one specific, non-limiting embodiment, theouter diameter 182 of the wear slug 180 is 4.5 inches, and the innerdiameter 184 of the wear slug 180 that mounts over the push-slug bolt136 is 1.0 inches. In this specific, non-limiting embodiment, theleading edge 186 of the wear slug 180 is 3.5 inches and the trailingedge 188 of the wear slug 180 is countersunk twice. In this embodiment,the first countersink is 0.25 inches deep and has a 4.0 inches diameter,and the second countersink is an additional 0.25 inches deep and has a3.5 inches diameter. Notably, these countersinks provide thetechnological improvement of assisting with the mount and center of thewear slug 180 on the leading end of the impact holder 130 (i.e., the endof the impact holder 130 in the direction of travel).

As described above, the outer diameter 182 of the wear slug 180 extendsbeyond the impact holder 130 to protect the impact holder 130 fromcomminution material 122 as the wear slug 180, impact cutter blade 150,and impact holder 130 rotate in the direction of travel of the cutterdisk 110 into the comminution material 122. Thus, the impact holder 130travels in the shadow of the wear slug 180 and is protected from themajority of the impact with the comminution material 122. Accordingly,the outer portion of the wear slug 180 (which is furthest from thecentral axis hole of the wear slug) receives the vast majority of theimpact with the comminution material 122 to about one third of the wearslug 180. Thus, the wear slug 180 may be rotated on the push-slug bolt136 into three approximate positions (i.e., thirds of the wear slugcircumference) before the wear slug 180 needs to be replaced orresurfaced.

In some embodiments, the wear slug 180 is made using a CNC (computernumerical control) lathe machine. Notably, the wear slug 180 may be madefrom mild steel and hard-faced, since a rough finish is acceptable forthe use of the wear slug 180. Hard-facing is a metalworking processwhere harder or tougher material is applied to a base metal to hardenand toughen the surface of the base material.

Referring now to FIGS. 2A, 2B, 3A, and 3C-3F, in another aspect of someembodiments, the impact cutter blade and holder system 100 includes aplurality of impact tabs 190. In such embodiments, the impact cutterblade and holder system 100 incorporate a plurality of impact tabs 190that protects the impact holders 130 from excessive damage caused by thetrailing edge 154 of the impact cutter blades 150 when encounteringcomminution material 122 (e.g., large pieces of metal). In previoussystems, the impact of comminution material 122 could swing (rotate) theimpact cutter blade 150 and cause damage to the portion of the blademounting slot 134 of the impact holder 130 that abuts with the trailingedge 154 of the impact cutter blade 150. Specifically, in previoussystems the impact of the comminution material 122 with the leading edge152 of the impact cutter blade 150 caused the impact cutter blade 150 toswing back in the opposite direction of the rotational travel of cutterdisk 110 and damage an old style holder.

The impact tab 190 has a leading end 192 and a trailing end 194(opposite the leading end 192, away from direction of travel). Theimpact tab 190 is positioned in an impact tab securing notch 160 in thetrailing edge 154 of the impact cutter blade 150, between the impactcutter blade 150 and the impact holder 130. The impact tab 190 ispositioned in an impact tab locating notch 144 of the impact holder 130.Thus, the leading end 192 of the impact tab 190 abuts the impact tabsecuring notch 160 in the trailing edge 154 of the impact cutter blade150, while the trailing end 194 of the impact tab 190 abuts the impacttab locating notch 144 of the impact holder 130.

As shown in FIG. 3A and 3C-3F, in the impact cutter blade and holdersystem 100, the trailing edge 154 of the impact cutter blade 150 issupported by the impact tab 190. Specifically, the impact cutter blade150 has an impact tab securing notch 160 in its trailing edge 154 thatholds the impact tab 190 in place. The 90-degree angle of this impacttab securing notch 160 enables the impact tab 190 to support the impactcutter blade 150 against both radial force and tangential forcesgenerated by impact of the impact cutter blade 150 with the comminutionmaterial 122 (which impacts the impact cutter blade 150 at manydifferent angles).

Impact tab locating notch 144 of the impact holder 130, which is wherethe impact tab 190 fits into the impact holder 130, is wider than theblade mounting slot 134 in the impact holder 130 for receiving theimpact bade 150. The back of the impact tab locating notch 144 of theimpact holder 130 serves to support the impact component that is pushingthe trailing edge of the impact bade 150 back into the impact holder130. With the impact tab 190 taking both components of the impact, theblade bolt 174 is protected from these forces. However, if the impacttab 190 is not employed, the blade bolt 174 will receive all of theseforces, and will have to be more robust to handle these forces.

In one embodiment, the impact tab 190 is placed in the impact tabsecuring notch 160 in the trailing edge 154 of impact cutter blade 150when the impact cutter blade 150 is inserted into the impact holder 130.Specifically, the impact tab 190 is positioned in an impact tab locatingnotch 144 of the impact holder 130. As the impact force (of the impactcutter blade 150 against the comminution material 122) swings the impactcutter blade 150 back in the opposite direction of the cutter disk'srotational travel about its central axis hole 118, the impact tab 190 ispinched between the trailing edge 154 of impact cutter blade 150 and thebearing surface (i.e., the impact tab locating notch 144) in the blademounting slot 134 of the impact holder 130.

The impact tab locating notch 144 engages the impact tab 190 to preventthe force of the impact (of the impact cutter blade 150 against thecomminution material 122) from pushing the trailing edge 154 of impactcutter blade 150 into the blade mounting slot 134 of the impact holder130. This force is countered by the impact tab locating notch 144 insidethe blade mounting slot 134 of the impact holder 130 that bears againstthe impact tab 190. Additionally, the 90-degree angle of this impact tabsecuring notch 160 (FIG. 3A) enables the impact tab 190 to support theimpact cutter blade 150 against additional forces (radial, normal,tangential, and the like) generated by impact of the impact cutter blade150 with the comminution material 122, which drive inward along thetrailing edge 154 of impact cutter blade 150.

In some embodiments, the impact tab 190 is a small piece of a metallicalloy that can be replaced when the impact cutter blade 150 is changed.Notably, the impact tab 190 can be reused if it is not damaged. Atechnological improvement of the impact cutter blade and holder system100 is that the impact tab 190 protects the blade mounting slot 134 ofthe impact holder 130 from damage from the trailing edge 154 of theimpact cutter blade 150 due to collision with comminution material 122.

In some embodiments, the impact tab 190 is formed from the same metallicalloy as the impact cutter blade 150. In other embodiments, the impacttab 190 is formed from a metallic alloy that is slightly softer than theimpact holder 130, thus resulting in the impact tab 190 deforming beforethe impact holder 130 (or impact cutter blade 150), which is desirablesince the impact tab 190 is easier (and more cost efficient) to replace.Accordingly, the easily replaceable impact tab 190 is constructed to bedamaged instead of the blade mounting slot 134 of the impact holder 130.

In some embodiments, the impact tab 190 is twice as wide as the trailingedge 154 of the impact cutter blade 150. The impact tab 190 protects theimpact holder 130 from being damaged/deformed by the trailing edge 154of the impact cutter blade 150, since the trailing edge 154 of theimpact cutter blade 150 is driven towards the impact holder 130 bycollision with the comminution material 122. The extended width of theimpact tab 190 (compared to the trailing edge 154 of the impact cutterblade 150) spreads out (and thereby diminishes) the force of thetrailing edge 154 of the impact cutter blade 150 towards the impactholder 130 by collision with the comminution material 122.

Notably, since the impact tab 190 presents twice as much surface area tothe bearing surface (impact tab locating notch 144) of the impact holder130 as the trailing edge 154 of the impact cutter blade 150, the impactcutter blade 150 forcibly abuts against the impact tab 190. The doubledsurface area of the impact tab 190 against the blade mounting slot 134of the impact holder 130 reduces the impacting force by half. Therefore,the impact tab 190 becomes deformed instead of the blade mounting slot134 of the impact holder 130.

Referring now to FIG. 6, in another aspect of some embodiments, theimpact cutter blade and holder system 100 includes disk wear cover plate200. In one embodiment, the disk wear cover plate 200 is formed from ametallic alloy that covers the entire top surface of the cutter disk 110and the impact holders 130. The disk wear cover plate 200 is mounted tothe cutter disk 110 using the cover plate holes 202 (shown in FIG. 1)and plate mounting bolts 204 that align with cover plate holes 202 inthe cutter disk 110. In one embodiment, the plate mounting bolts 204 aretightened to 400-500 ft. lbs. of torque. The disk wear cover plate 200has an upper surface 206 (away from the cutter disk 110) that comes intocontact with comminution material 122. Additionally, the disk wear coverplate 200 has a lower surface (not shown) facing the cutter disk 110that does not come into contact with comminution material 122. Notably,the disk wear cover plate 200 has a smooth surface. Furthermore, thedisk wear cover plate 200 does not require the strength levels of theother parts described herein since contact/collision of the disk wearcover plate 200 with the comminution material 122 tends to be tangentialrather than direct.

Since the disk wear cover plate 200 does not receive as much impact(with the comminution material 122) as the impact holders 130 and impactcutter blade 150, in some embodiments the disk wear cover plate 200 ismade of a wear-resistant alloy that is harder (but not as high strengthas the cutter blade 110. This type of wear-resistant alloy is lessexpensive than the high strength alloys (of which the cutter disk 110,impact holders 130, and impact cutter blades 150 are typically made),thus, making the disk wear cover plate 200 more practical as areplaceable part.

A significant, unexpected technological benefit of the disk wear coverplate 200 is that its upper surface 206 is much flatter and smootherthan the bare cutter disk 110. This flat, smooth surface of the diskwear cover plate 200 drastically reduces friction, energy consumption(e.g., horsepower requirements), and fuel burn since contact/collisionof the disk wear cover disk 200 with the comminution material 122 isoblique rather than direct. Without the implementation of the disk wearcover plate 200, the top surface of the cutter disk 110 and the top sideof the impact holders 130 had to be regularly repaired due to damagefrom impact with comminution material 122. In some embodiments, the diskwear cover plate 200 is removable and can be rehardfaced and reused.Notably, the disk wear cover plate 200 almost completely eliminates thehardfacing maintenance of the cutter disk 110 and the top side of theimpact holders 130.

Another implementation of an impact cutter blade and holder system 100is intended mostly for smaller machines that are operated in materialsthat have low abrasive content. In this implementation, the impactholders are formed as part of the cutter disk by welding (or otherwisesecuring) holder blocks to produce a one-piece cutter disk. The “holderblocks” have all the features of an impact holder to secure anassociated impact cutter blade. In some embodiments, the holder blocksare welded to the cutter disk at various angles then hardfaced toproduce finished holder blocks.

In at least one implementation, the one-piece cutter disk is made bywelding the holder blocks into a solid cutter disk at various angles.The one-piece cutter disk provides a technological improvement ofincreased production efficiency. However, the one-piece cutter disktypically must be removed from the refiner for hardfacing maintenance,instead of only removing the impact holders, wear plates, and wearslugs. In some embodiments, the one-piece cutter disk is held in placewith a wing nut. Tree service companies are an example where thecomminution material 122 (e.g., stumps chunks and tree limbs) isrelatively free of harder contaminates. In this tree serviceimplementation, the one-piece cutter disk may only need maintenanceafter months of service, whereas in a garbage service implementation,maintenance may be required on a weekly or even daily basis due to theprevalence of harder contaminates and comminution material 122.

In still other alternate embodiments of the impact cutter blade andholder system 100, the shape of the impact cutter blades 150 aremodified, but the manner in which the impact cutter blades 150 areclamped to reduce vibration and provide maximum rigidity at the leadingedge 152 or cutting point is maintained. The following embodimentsdescribe several approaches by which the impact cutter blades 150 andimpact holders 130 can be produced that provide the technologicalimprovements associated with clamping to reduce vibration and providemaximum rigidity at the leading edge 152 of the impact cutter blades150.

In a first alternate embodiment of impact cutter blade and holder system100, the blade bolt hole 162 through the impact cutter blade 150 ismoved closer to the trailing edge 154. This movement of the blade bolthole 162 closer to the trailing edge 154 of the impact cutter blade 150enables a nut to be employed for securing the blade bolt 174 whichprovides the proper clamping without the need for the nut to be astepped nut. However, this configuration with the blade bolt hole 162moved closer to the trailing edge 154 of the impact cutter blade 150would not be as strong since the blade bolt 174 must be smaller in thislocation (due to space limitations).

In a second alternate embodiment of impact cutter blade and holdersystem 100, each impact cutter blade 150 includes two blade bolt holes162 which are secured with corresponding stepped nuts 172 to generateproper clamping, which reduces vibration and provides maximum rigidityat the leading edge 152 of the impact cutter blades 150. In stillanother implementation, the two blade bolt holes 162 are positionedcloser to the trailing edge 154 of the impact cutter blades 150 (asdescribed above in the first alternate embodiment) and provide theproper clamping without stepped nuts.

In a third alternate embodiment of impact cutter blade and holder system100, the holder fulcrum 146 (e.g., pivot ridge) is located in the blademounting slot 134 of the impact holders 130 (instead of on the impactcutter blade 150). The holder fulcrum 146 is a bottom-facing fulcrum onthe top side of the blade mounting slot 134. This alternate embodimentmay also include an opposite side contact fulcrum or pivot ridge 166 onthe impact cutter blade 150 as shown on the thin impact cutter blade 150a in FIG. 3E. In another embodiment, the pivot ridge 166 is areplaceable pin-like shape that is separate from the impact holder 130and the impact cutter blade 150. In still another implementation, thepivot ridge 166 is a piece of key stock that is position in a groove ofthe impact holder 130 and/or the impact cutter blade 150.

In a fourth alternate embodiment of impact cutter blade and holdersystem 100, the impact cutter blade 150 does not have a blade bolt hole162 in it. Rather, the clamping force is provided by a bolt that isthreaded into the impact holder 130, with the point of the threaded bolttransmitting pressure at a correct spot. In still anotherimplementation, the impact cutter blade 150 has a small hole (or atleast an indentation) into which the threaded bolt could extend.Notably, these embodiments all employ the unique combination of aclamping action (to reduce vibration and provide maximum rigidity at theleading edge of the impact cutter blades), via a clamp point (orpoints), a pivot ridge, and an opposing leading edge contact line orridge.

In some embodiments of an impact cutter blade and holder method, theclamping of the impact cutter blades 150 in the impact holders 130achieves unique technological improvements. The combination ofcooperating impact cutter blade details and impact holders details areused to achieve the proper clamping to reduce vibration and providemaximum rigidity at the leading edge of the impact cutter blades.

In some embodiments of the impact cutter blade and holder system 100,the impact cutter blade and holder system 100 includes a cutter disk110; a plurality of impact holders 130; a plurality of impact cutterblades 150, wherein an impact cutter blade 150 is attached to eachimpact holder 130; and a plurality of wear slugs 180, wherein a wearslug 180 is attached to each impact holder 130.

In other embodiments of the impact cutter blade and holder system 100,the impact cutter blade and holder system 100 includes a cutter disk110; a plurality of impact holders 130; a plurality of impact cutterblades 150, wherein an impact cutter blade 150 is attached to eachimpact holder 130; and a plurality of impact tabs 190, wherein an impacttab 190 is secured between each impact holder 130 and associated impactcutter blade 150.

In still other embodiments of the impact cutter blade and holder system100, the impact cutter blade and holder system 100 includes a cutterdisk 110; a plurality of impact holders 130; a plurality of impactcutter blades 150, wherein an impact cutter blade 150 is attached toeach impact holder 130; and a disk wear cover plate 200.

Yet other embodiments are directed towards the impact holder 130 itself.In such an embodiment, the impact holder 130 secures to a cutter disk110; an impact cutter blade 150, and an impact tab 190. The impactcutter blade 150 is attached to the impact holder 130, while the impacttab 190 is secured between the impact holder 130 and the impact cutterblade 150.

Certain words and phrases used in the specification are set forth asfollows. As used throughout this document, including the claims, thesingular form “a”, “an”, and “the” include plural references unlessindicated otherwise. Any of the features and elements described hereinmay be singular, e.g., a sensor may refer to one sensor and a memory mayrefer to one memory. The terms “include” and “comprise,” as well asderivatives thereof, mean inclusion without limitation. The term “or,”is inclusive, meaning and/or. The phrases “associated with” and“associated therewith,” as well as derivatives thereof, may mean toinclude, be included within, interconnect with, contain, be containedwithin, connect to or with, couple to or with, be communicable with,cooperate with, interleave, juxtapose, be proximate to, be bound to orwith, have, have a property of, or the like. Other definitions ofcertain words and phrases are provided throughout this patent document.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimit of that range and any other stated or intervening value in thatstated range is encompassed within the invention. The upper and lowerlimits of these smaller ranges may independently be included in thesmaller ranges is also encompassed within the invention, subject to anyspecifically excluded limit in the stated range. Where the stated rangeincludes one or both of the limits, ranges excluding either or both ofthose included limits are also included in the present disclosure.

Generally, unless otherwise indicated, the materials for making theinvention and/or its components may be selected from appropriatematerials such as metal, metallic alloys (high strength alloys, highhardness alloys), composite materials, ceramics, intermetalliccompounds, and the like.

The foregoing description, for purposes of explanation, uses specificnomenclature and formula to provide a thorough understanding of thedisclosed embodiments. It should be apparent to those of skill in theart that the specific details are not required in order to practice theinvention. The embodiments have been chosen and described to bestexplain the principles of the disclosed embodiments and its practicalapplication, thereby enabling others of skill in the art to utilize thedisclosed embodiments, and various embodiments with variousmodifications as are suited to the particular use contemplated. Thus,the foregoing disclosure is not intended to be exhaustive or to limitthe invention to the precise forms disclosed, and those of skill in theart recognize that many modifications and variations are possible inview of the above teachings.

These and other changes can be made to the embodiments in light of theabove-detailed description. In general, in the following claims, theterms used should not be construed to limit the claims to the specificembodiments disclosed in the specification and the claims, but should beconstrued to include all possible embodiments along with the full scopeof equivalents to which such claims are entitled. Accordingly, thebreadth and scope of a disclosed embodiment should not be limited by anyof the above-described exemplary embodiments, but should be defined onlyin accordance with the following claims and their equivalents.

1. An impact cutter blade and holder system, comprising: a cutter diskhaving a central axis about which the cutter disk is configured torotate; a plurality of impact holders, wherein each of the plurality ofimpact holders is secured to the cutter disk; a plurality of impactcutter blades, wherein an associated impact cutter blade of theplurality of impact cutter blades is secured to an associated impactholder of the plurality of impact holders; a plurality of wear slugs,wherein an associated wear slug of the plurality of wear slugs issecured to the associated impact holder of the plurality of impactholders, and wherein the associated wear slug is shaped, sized, andsecurely positioned to shield the associated impact holder of theplurality of impact holders from damage by comminution material; aplurality of impact tabs, wherein an associated impact tab of theplurality of impact tabs is secured between the associated impact holderand the associated impact cutter blade, and wherein the associatedimpact tab of the plurality of impact tabs is shaped, sized, andsecurely positioned to shield the associated impact holder from atrailing edge of the associated impact cutter blade due to collision ofthe associated impact cutter blade with the comminution material; and adisk wear cover plate secured to the cutter disk, wherein the disk wearcover plate is shaped and sized to shield the cutter disk and thesecured plurality of impact holders from damage by the comminutionmaterial.
 2. An impact cutter blade and holder system, comprising: acutter disk having a central axis about which the cutter disk isconfigured to rotate; a plurality of impact holders, wherein each of theplurality of impact holders is secured to the cutter disk; a pluralityof impact cutter blades, wherein an associated impact cutter blade ofthe plurality of impact cutter blades is secured to an associated impactholder of the plurality of impact holders; and a plurality of wearslugs, wherein an associated wear slug of the plurality of wear slugs issecured to the associated impact holder of the plurality of impactholders, and wherein the associated wear slug is shaped, sized, andsecurely positioned to shield the associated impact holder of theplurality of impact holders from damage by comminution material.
 3. Theimpact cutter blade and holder system of claim 2, wherein each of theplurality of impact holders contains a holder bolt hole for receiving ablade bolt, and a blade mounting slot for receiving a held end of animpact cutter blade.
 4. The impact cutter blade and holder system ofclaim 2, wherein the associated impact holder of the plurality of impactholders includes a push-slug bolt, wherein the push-slug bolt tightensthe associated wear slug in place.
 5. The impact cutter blade and holdersystem of claim 2, wherein the associated impact cutter blade of theplurality of impact cutter blades has a leading edge positioned tocollide with the comminution material and a trailing edge opposite theleading edge, wherein the associated impact cutter blade has a cutterend that is located away from the associated impact holder and a heldend that is secured in the associated impact holder.
 6. The impactcutter blade and holder system of claim 2, wherein the associated impactcutter blade of the plurality of impact cutter blades contains a bladebolt hole for securing the associated impact cutter blade to theassociated impact holder using the blade bolt hole, wherein a blade boltis positioned through the blade bolt hole.
 7. The impact cutter bladeand holder system of claim 6, wherein the associated impact cutter bladeof the plurality of impact cutter blades is secured through the bladebolt hole of the associated impact cutter blade to the associated impactholder using the blade bolt and a stepped nut, wherein the stepped nuthas a lower portion and a stepped portion that is raised higher than thelower portion of the stepped nut, and wherein the stepped portion of thestepped nut contacts the associated impact cutter blade on a trailingedge of the blade bolt hole.
 8. The impact cutter blade and holdersystem of claim 7, wherein a hex hole secures the stepped nut whichenables the blade bolt to be removed with a single wrench.
 9. The impactcutter blade and holder system of claim 8, wherein the associated impactcutter blade of the plurality of impact cutter blades includes a ridgethat runs along a length of the associated impact cutter blade and actsas a fulcrum when the associated impact cutter blade is secured in ablade mounting slot of the associated impact holder.
 10. The impactcutter blade and holder system of claim 9, wherein the blade bolt istightened against the stepped nut, which generates leverage against thefulcrum that forces a leading edge of the associated impact cutter bladeagainst a forward opposite side of the blade mounting slot in theassociated impact holder.
 11. The impact cutter blade and holder systemof claim 10, wherein the leverage provides tension that keeps the bladebolt from coming loose.
 12. The impact cutter blade and holder system ofclaim 2, wherein the associated wear slug of the plurality of wear slugsis mounted to the associated impact holder via a machine fit, whereinthe push-slug bolt tightens the associated wear slug in place.
 13. Theimpact cutter blade and holder system of claim 12, wherein theassociated wear slug of the plurality of wear slugs is larger indiameter at the push-slug bolt than the associated impact holder,wherein the associated wear slug presents a larger profile to incomingcomminution material than the associated impact holder, and wherein theassociated wear slug protects the associated impact holder by shieldingthe associated impact holder from collisions with the incomingcomminution material that would otherwise damage the associated impactholder.
 14. The impact cutter blade and holder system of claim 2,wherein the associated wear slug that is mounted on the associatedimpact holder only exposes a third of a circumference of the associatedwear slug to collision with the comminution material, and wherein theassociated wear slug is rotatable to at least three separate positionswhile shielding the associated impact holder, each position representinga third of the circumference of the associated wear slug.
 15. An impactcutter blade and holder system, comprising: a cutter disk having acentral axis about which the cutter disk is configured to rotate; aplurality of impact holders, wherein each of the plurality of impactholders is secured to the cutter disk; a plurality of impact cutterblades, wherein an associated impact cutter blade of the plurality ofimpact cutter blades is secured to an associated impact holder of theplurality of impact holders; and a plurality of impact tabs, wherein anassociated impact tab of the plurality of impact tabs is secured betweenthe associated impact holder and the associated impact cutter blade, andwherein the associated impact tab of the plurality of impact tabs isshaped, sized, and securely positioned to shield the associated impactholder from a trailing edge of the associated impact cutter blade due tocollision of the associated impact cutter blade with comminutionmaterial.
 16. The impact cutter blade and holder system of claim 15,wherein each of the plurality of impact holders contains a holder bolthole for receiving a blade bolt, and a blade mounting slot for receivinga held end of the associated impact cutter blade.
 17. The impact cutterblade and holder system of claim 15, wherein the associated impactholder further includes an impact tab locating notch for locating theassociated impact tab, wherein the impact tab locating notch is wider asthe trailing edge of the associated impact cutter blade.
 18. The impactcutter blade and holder system of claim 15, wherein the associatedimpact cutter blade of the plurality of impact cutter blades has aleading edge positioned to collide with the comminution material and atrailing edge opposite the leading edge, wherein the associated impactcutter blade has a cutter end that is located away from the associatedimpact holder and a held end that is secured in the associated impactholder.
 19. The impact cutter blade and holder system of claim 18,wherein the associated impact cutter blade of the plurality of impactcutter blades includes an impact tab securing notch on the trailing edgeof the associated impact cutter blade.
 20. The impact cutter blade andholder system of claim 15, wherein the associated impact cutter blade ofthe plurality of impact cutter blades contains a blade bolt hole forsecuring the associated impact cutter blade to the associated impactholder using the blade bolt hole, wherein a blade bolt is positionedthrough the blade bolt hole.
 21. The impact cutter blade and holdersystem of claim 20, wherein the associated impact cutter blade of theplurality of impact cutter blades is secured through the blade bolt holeof the associated impact cutter blade to the associated impact holderusing the blade bolt and a stepped nut, wherein the stepped nut has alower portion and a stepped portion that is raised higher than the lowerportion of the stepped nut, and wherein the stepped portion of thestepped nut contacts the associated impact cutter blade on a trailingedge of the blade bolt hole.
 22. The impact cutter blade and holdersystem of claim 20, wherein a hex hole secures the stepped nut whichenables the blade bolt to be removed with a single wrench.
 23. Theimpact cutter blade and holder system of claim 21, wherein theassociated impact cutter blade of the plurality of impact cutter bladesincludes a ridge that runs along a length of the associated impactcutter blade and acts as a fulcrum when the associated impact cutterblade is secured in a blade mounting slot of the associated impactholder.
 24. The impact cutter blade and holder system of claim 23,wherein the blade bolt is tightened against the stepped nut, whichgenerates leverage against the fulcrum that forces a leading edge of theassociated impact cutter blade against a forward opposite side of theblade mounting slot in the associated impact holder.
 25. The impactcutter blade and holder system of claim 24, wherein the leverageprovides tension that keeps the blade bolt from coming loose.
 26. Theimpact cutter blade and holder system of claim 15, wherein theassociated impact tab of the plurality of impact tabs shields theassociated impact holder from damage caused by the trailing edge of theassociated impact cutter blade when the associated impact cutter bladeencounters the comminution material.
 27. The impact cutter blade andholder system of claim 15, wherein the associated impact tab ispositioned in an impact tab securing notch in the trailing edge of theassociated impact cutter blade, between the associated impact cutterblade and the associated impact holder, and wherein the associatedimpact tab is positioned in an impact tab locating notch of theassociated impact holder.
 28. The impact cutter blade and holder systemof claim 27, wherein a leading end of the associated impact tab abutsthe impact tab securing notch in the trailing edge of the associatedimpact cutter blade, while a trailing end of the associated impact tababuts the impact tab locating notch of the associated impact holder. 29.The impact cutter blade and holder system of claim 15, wherein theassociated impact cutter blade of the plurality of impact cutter bladeshas an impact tab securing notch with a 90-degree angle in a trailingedge of the associated impact cutter blade that holds the associatedimpact tab in place, wherein the 90-degree angle of the impact tabsecuring notch enables the associated impact tab to support theassociated impact cutter blade against forces in multiple directions.30. The impact cutter blade and holder system of claim 15, wherein theassociated impact tab of the plurality of impact tabs has a larger widththan a trailing edge of the associated impact cutter blade, wherein thelarger width of the associated impact tab spreads out and diminishesforces transmitted by the associated impact cutter blade towards theassociated impact holder due to collision of the associated impactcutter blade with the comminution material.
 31. The impact cutter bladeand holder system of claim 15, wherein the associated impact tab of theplurality of impact tabs is formed from a metallic alloy that is softerthan the associated impact holder such that force from the associatedimpact cutter blade deforms the associated impact tab before theassociated impact holder.
 32. An impact cutter blade and holder system,comprising: a cutter disk having a central axis about which the cutterdisk is configured to rotate; a plurality of impact holders, whereineach of the plurality of impact holders is secured to the cutter disk; aplurality of impact cutter blades, wherein an associated impact cutterblade of the plurality of impact cutter blades is secured to anassociated impact holder of the plurality of impact holders; and a diskwear cover plate secured to the cutter disk, wherein the disk wear coverplate is shaped and sized to shield the cutter disk and the securedplurality of impact holders from damage by comminution material.
 33. Theimpact cutter blade and holder system of claim 32, wherein the disk wearcover plate is secured to the cutter disk using plate mounting bolts,and wherein the disk wear cover plate reduces friction, energyconsumption, and fuel consumption since collision against the disk wearcover plate by the comminution material is oblique rather than direct.34. An impact cutter blade clamping method using an impact cutter bladeand holder system, the method comprising: providing a cutter disk and aplurality of impact holders, wherein the cutter disk has a central axisabout which the cutter disk is configured to rotate, and wherein each ofthe plurality of impact holders is secured to the cutter disk;configuring the plurality of impact holders to include blade mountingslots, wherein each blade mounting slot includes sidewalls and is shapedand sized to receive an impact cutter blade, and wherein the impactcutter blade includes two impact cutter blade sidewalls and a leadingedge that is positioned to intersect with comminution material when thecutter disk rotates; positioning a ridge on at least one of an impactcutter blade sidewall or a blade mounting slot sidewall of an associatedimpact holder of the plurality of impact holders; placing the impactcutter blade in the blade mounting slot of the associated impact holder;clamping, using a blade bolt, the impact cutter blade to the associatedimpact holder and against the ridge, which acts as a fulcrum thatreduces vibration and provides increased rigidity at the leading edge ofthe impact cutter blade; and generating leverage against the fulcrumthat forces the leading edge of the associated impact cutter bladeagainst a forward opposite sidewall of the blade mounting slot in theassociated impact holder.
 35. The method of claim 34, wherein the bladebolt is tightened against a stepped nut that is positioned opposite ofthe ridge on at least one of an impact cutter blade sidewall or a blademounting slot sidewall of an associated impact holder of the pluralityof impact holders.